Introduction

When we think about workplace hazards, most of us imagine chemical spills, sharp tools, or slips and falls. But there’s another risk that often goes unnoticed until it’s too late—hazardous energy.

Every year, many workplace accidents happen because workers are exposed to uncontrolled energy during maintenance or routine tasks. In Ohio, one such incident occurred when a hydraulic press suddenly activated while a worker was performing maintenance. The stored hydraulic energy caused the press to crush the worker’s hand, resulting in multiple fractures. OSHA later cited the company for not properly isolating the energy source before starting the work.

Clearly, the real challenge is that hazardous energy is not always obvious. It doesn’t just come from electrical lines. Yes, it can hide in pressurized systems, stored chemicals, heated equipment, and even in the movement of heavy machines.

So, the big question is, what exactly counts as hazardous energy? Most importantly, how can organizations handling chemical products identify and control them?

Continue reading this guide to gain a thorough understanding of hazardous energy. Let’s begin!

What is Hazardous Energy?

Hazardous energy refers to any type of energy (stored or active) that can cause harm to workers if it is released unexpectedly. This includes energy sources such as electricity, mechanical parts, hydraulic pressure, compressed air (pneumatic), chemicals, or heat.

These types of energies can release suddenly when machines or equipment are being serviced or maintained. The sudden startup or release of this energy can lead to severe injuries or even fatalities. That’s why OSHA highlights the importance of safety practices like Lockout/Tagout (LOTO), which are designed to control hazardous energy and protect workers from accidental exposure.

The Different Forms of Hazardous Energy

1. Electrical Energy

Electrical energy is one of the most common and dangerous hazards in workplaces. It can come from live wires, overloaded circuits, or even stored energy in equipment like capacitors and batteries.

Risks: Workers can suffer electric shocks, serious burns, or even fatal electrocution if they come into contact with uncontrolled electricity.

2. Mechanical Energy

Mechanical energy is stored in moving parts or equipment with springs, flywheels, or rotating blades. Even when machines are turned off, parts may still be under tension or capable of sudden movement.

Risks: Workers may face crushing injuries, pinching, or entanglement in moving machinery if energy is not properly controlled.

3. Thermal Energy (Heat and Cold)

Thermal energy comes from equipment that produces or stores heat, like boilers, ovens, or furnaces. Extreme cold from cryogenic systems or refrigeration units can also be dangerous.

Risks: Exposure can lead to burns, scalds, or frostbite, depending on whether the temperature is extremely high or low.

4. Hydraulic Energy

Hydraulic systems use pressurized liquids to operate machines such as lifts, presses, or chemical processing equipment. Even after shutting down, trapped pressure can remain in hoses or cylinders.

Risks: A sudden release of hydraulic pressure can crush body parts, cause puncture wounds, or lead to equipment failure.

5. Pneumatic Energy

Pneumatic energy is stored in compressed air or gases used in tools, pipelines, and industrial equipment. Like hydraulic systems, pressure can remain even when the system looks idle.

Risks: Accidents may include hose whip, parts flying off, or dangerous chemical release.

6. Chemical Energy

Chemical energy is particularly important for industries handling hazardous substances. It comes from stored chemicals, chemical reactions, or flammable vapors.

Risks: If not controlled, this energy can lead to fires, explosions, toxic gas leaks, or violent reactions.

7. Gravitational Energy

Gravitational energy exists whenever an object is lifted or suspended, like hoisted loads, elevated machine parts, or chemical drums lifted by cranes.

Risks: If the object falls, it can crush, injure, or even kill workers below.

Why is Identifying Hazardous Energy Important?

Prevents Accidents: Many workplace injuries happen because energy sources weren’t identified. For example, if workers don’t know a machine still holds stored electrical charge, it can shock them when touched. By spotting these hidden dangers early, accidents can be avoided.

Protects Workers: Workers are the most exposed when dealing with equipment and chemicals. Identifying hazardous energy helps them understand what risks exist (whether it’s a pressurized line, a hot surface, or a suspended load). It helps them take precautions before starting any task.

Supports Control Measures: Safety practices like Lockout/Tagout (LOTO) only work if you know which energy sources to control. Without identifying the right electrical circuits, valves, or switches, the controls may fail, leaving dangerous energy still active.

Reduces Equipment Damage: Unexpected releases of energy don’t just hurt people; they can also damage machines. For instance, a hydraulic pressurization that’s not discharged properly can harm internal parts or even cause costly breakdowns. Identifying energy sources keeps equipment safe, too.

Ensures Compliance: OSHA and other regulators require organizations to document and control hazardous energy. Failure to identify and manage it can lead to violations, heavy fines, and reputational damage. Proper identification shows you are compliant and serious about safety.

Builds a Safer Workplace: When workers are trained to recognize hazardous energy, it creates a culture of awareness. People start watching out not just for themselves but also for their teammates, which leads to fewer incidents and a stronger safety record overall.

How Can Organizations Control Hazardous Energy?

Here are some key steps:

Energy Identification: Start by mapping all possible energy sources in your facility.

Lockout/Tagout (LOTO): Implement a robust LOTO program to isolate and control energy during servicing.

Training: Train employees to recognize hazardous energy and follow safe practices.

Regular Audits: Continuously monitor systems and processes to ensure compliance.

Emergency Preparedness: Have clear procedures for responding to accidental releases.

Conclusion

Hazardous energy exists all around chemical-handling industries—whether in electrical systems, pressurized tanks, or heavy machinery. The real danger lies not only in its presence but also in its sudden, uncontrolled release when safety procedures are overlooked or equipment fails.

When organizations understand the different forms of hazardous energy, they can put the right controls in place, protect their workforce, and strengthen a culture where safety comes first.